OSMONICSE4, E4LE, EZ4 SERIESTM

WATER PURIFICATIONMACHINES

INSTALLATION, OPERATION,AND MAINTENANCE

MANUAL

GE InfrastructureWater & Process Technologies

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

E4, E4LE, AND EZ4 SERIESWATER PURIFICATION MACHINES

TABLE OF CONTENTS

Page

2.0 INSTALLATION 1

2.1 Mounting the Unit 12.2 Plumbing 12.3 Installing Clean-In-Place Valves 22.4 Concentrate Outlet Connections 22.5 Feed Water Requirements 22.6 Transporting Pure Water (Permeate) to Point-of-Use 32.7 Pressure Correction Factors 42.8 Electrical 5

2.8.1 Single-Phase Electrical 52.8.2 Three-Phase Electrical 5

2.9 Machine Control 62.9.1 Economy Model 62.9.2 Deluxe Model 6

2.10 Pretreatment for Water Purification 72.11 Machine Start-Up Preparation 72.12 Machine Start-Up 72.13 Temperature Correction Factors 92.14 Recovery 102.15 Autoflush Timer 11

2.15.1 Programming the Autoflush Timer 112.15.2 Setting-Up the Autoflush Timer Clock 112.15.3 Programming the Autoflush Timer Clock 122.15.4 Programming Twenty-Four Hour or Seven Day Schedules 132.15.5 Changing a Program 132.15.6 Deleting a Program 132.15.7 Troubleshooting the Autoflush Timer 14

2.16 Calibrating the Conductivity Probe 15

Page

2.17 Operation and Maintenance 162.17.1 Daily Flushing for the Economy Model 162.17.2 Daily Flushing for the Deluxe Model 16

2.18 Pre-Filter Cartridge 172.19 Membrane Element Cleaning 17

2.19.1 Step Wise Cleaning 172.19.2 Procedure to Clean with a CIP Pump 17

2.20 Suction Cleaning 192.21 Changing Out Membrane Elements 202.22 Troubleshooting 22

LIST OF FIGURES

Figure Description

2.1 Three-Phase Allen Bradley Motor Starter 62.2 Setting-Up the Correct Time on the Autoflush Timer 112.3 Programming the Timer 132.4 Conductivity Probe Display 152.5 Clean-In-Place Pump and Tank Hook-Up 18

LIST OF TABLES

Table Description

2.1 Connections 12.2 E-Series Feed Water Requirements 32.3 Pressure Correction Factors 42.4 Flow Specifications for E4-Series Machines 10

1

2.0 INSTALLATION

2.1 Mounting the Unit

When installing your new GE Infrastructure Water & Process Technologies reverseosmosis (RO) machine, allow at least 45-inches (114 cm) above the machine for mem-brane element removal and loading. If space is not available, the entire membraneelement housing can be removed for membrane element change outs. If the mem-brane element housings are to be removed to change out the membrane elements,at least 6-inches (15.2 cm) is required at the end of each membrane element housingand 24-inches (61 cm) behind the machine.

2.2 Plumbing

The feed water source must be able to provide water quantity and pressures to main-tain an operating feed water pressure of 30 - 60 psig (2.1 - 4.1 barg). If the feed waterpressure with the machine is in excess of 60 psig (4.1 barg) or fluctuates by more than5 psig (0.34 barg) a pressure regulator should be installed up stream of the machineInlet. If proper water pressure cannot be maintained to the RO, a booster pump mayneed to be installed in front of the pretreatment to provide the proper water quantityand pressure for the operation of the machine.

Table 2.1Connections

* Low Energy Membrane Elements

INLETinches (cm)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

E4/EZ4/E4LE*MACHINE

2200

4400

6600

8800

11000

13200

PERMEATEinches (cm)

0.50 (1.27)

0.50 (1.27)

0.50 (1.27)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

CONCENTRATEinches (cm)

0.50 (1.27)

0.50 (1.27)

0.50 (1.27)

0.75 (1.90)

0.75 (1.90)

0.75 (1.90)

2.3 Installing Clean-In-Place Valves

NOTE: Clean-In-Place (CIP) valves are not included with the machine. The CIPvalves must be purchased and installed by the customer.

When installing the CIP valves, a three-way valve should be installed in the inlet feedstream of the machine. The tees on the permeate and concentrate lines should beinstalled with two-way valves. All valves should be installed in a manner that willallow circulation of the cleaning chemicals through the machine and back to the CIPcontainer during cleaning.

CAUTION: If CIP valves are not installed when machine is installed, provisionsmust be made to bypass permeate and concentrate to drain for flush-ing at start-up.

WARNING: NEVER OPERATE THE MACHINE WITH THE CONCENTRATE OR PER-MEATE LINES BLOCKED. SEVERE DAMAGE TO THE UNIT MAY RESULT.

2.4 Concentrate Outlet Connections

Connect proper size drain line to the concentrate outlet (Table 2.1) and run to an opendrain. The drain capacity needs to be large enough to properly drain the feed waterflow of the RO. The maximum concentrate back pressure is 60 psig (4.1 barg) for theRO machine.

CAUTION: Operation above 60 psig (4.1 barg) concentrate back pressure maydamage the machine.

2.5 Feed Water Requirements

The following feed water requirements must be met before installing your new E4machine to ensure quality permeate and extended membrane element life. Refer toTable 2.2 (E-Series Feed Water Requirements) for feed water information.

2

Table 2.2E-Series

Feed Water Requirements

* American Standard for Testing Materials

2.6 Transporting Pure Water (Permeate) to Point-of-Use

The pure water, or permeate, is in an aggressive state and should only be transport-ed from the machine to the point-of-use in food grade flexible nylon, stainless steel(SS) tubing, or polyvinyl chloride (PVC) material for the inlet, permeate, and concen-trate piping sizes. Refer to Connections (Table 2.1) for inlet, permeate, and concen-trate piping sizes.

WARNING: MACHINE DAMAGE MAY OCCUR IF PERMEATE BACK PRESSUREEXCEEDS 60 PSIG (4.1 BARG) DURING OPERATION.

3

Temperature

Inlet Pressure

Chlorine(continuous feed)

Operating pH

Silt Density Index (SDI)

Typical: 50° - 85°F (10° - 29°C)Limits: 33° - 104°F (0.16° - 40°C)

Minimum: 30 psig (2.1 barg)Maximum: 60 psig (4.1 barg)

0 parts per million (ppm)

5.5 - 8.5

Less than or equal to 5 to minimizemembrane element fouling andextend cleaning intervals.Refer to ASTM* standard D4189.

2.7 Pressure Correction Factors

It is often necessary to operate RO machines with permeate back pressure. Permeateback pressure will decrease permeate production. See Table 2.3 (Pressure CorrectionFactors) to calculate loss of permeate.

Table 2.3Pressure Correction

Factors

WARNING: IF PERMEATE BACK PRESSURE EXCEEDS 60 PSIG (4.1 BARG)MACHINE DAMAGE MAY OCCUR.

WARNING: INSTALLING A CHECK VALVE WILL PREVENT REVERSE FLOWTHROUGH THE MEMBRANE ELEMENT WHEN THE MACHINE IS NOTIN OPERATION. REVERSE FLOW, WHEN THE MACHINE IS NOT INOPERATION, CAN SEVERELY DAMAGE THE MEMBRANE ELEMENTS.

4

BACK PRESSURE

10 psig (0.7 barg)

20 psig (1.4 barg)

30 psig (2.0 barg)

40 psig (2.7 barg)

50 psig (3.4 barg)

60 psig (4.1 barg)

% LOSS OFPERMEATE FLOW

E4/EZ4 E4LE

5% 10%

10% 20%

15% 30%

20% 40%

25% 50%

30% 60%

PRESSURECORRECTIONFACTOR (PCF)

E4/EZ4 E4LE

0.95 0.90

0.90 0.80

0.80 0.70

0.70 0.60

0.60 0.50

0.50 0.40

2.8 Electrical

This RO machine requires two supply voltages; the control voltage and thepump motor voltage.

2.8.1 Single-Phase Electrical

The control voltage can be connected to either a 115 VAC, 60 Hertz or220 VAC, 50 Hertz single-phase power supply. The RO control circuitshould always be installed on at least a 15 Amp, single-phase dedi-cated circuit. Reverse osmosis machines with 115 VAC, single-phasecontrol voltage include an eight-foot (2.4 m) cord which plugs into athree-prong grounded receptacle. All machines shipped with a220 VAC, single-phase control circuit are shipped with an eight-footelectrical cord, but customers must provide electrical plug.

2.8.2 Three-Phase Electrical

The three-phase pump motor requires a 15 AMP dedicated circuit.Always verify correct voltage and Amp rating by checking voltage tagon the starter box or by checking electrical specifications on thepump. The motor is wired for 460 Volts, 60 Hertz, three-phase voltagefrom the factory (Figure 2.1, Three-Phase Allen Bradley Motor Starter).The pump motor can be rewired to 208 or 230 Volts. If this is done, awiring change must be made internally in the pump motor and ahigher amperage relay and starter may need to be installed. All fieldwiring must comply with applicable local and national electricalcodes.

After checking the voltage tag on the motor starter to ensure theavailable voltage and amperage are correct, connect the providedthree-phase power to the motor starter (Figure 2.1). This can be doneby connecting the three phase power to the top of the starter relayterminals: L1, L2, and L3. A separate, fused disconnect for the motorwiring with proper protection for the Horsepower and Amp draw ofthe motor is recommended. All field wiring must comply with applic-able local and national electrical codes. See Figure 2.1 for three-phase Allen Bradley Starter Hook-Up.

5

Figure 2.1Three-Phase

Allen Bradley Motor Starter

2.9 Machine Control

2.9.1 Economy Model

To remotely control the Economy Model (ECN) with float switches and/or pre-treatment lockout, remove the jumper between terminals 4 and 5 and wire inthe float switches or pretreatment components in series. After all field wiringis complete and complies with local and national electrical codes, move ontoSection 2.10 (Pretreatment for Water Purification).

NOTE: External control contacts are normally closed, dry contacts.

2.9.2 Deluxe Model

To remotely control the Deluxe Model (DLX), with float switches and/or pre-treatment lockout, remove the jumper between terminals 2 and 3 and wire inthe float switches and pretreatment in series. After all field wiring is complete

6

7

and complies with local and national electrical codes, move onto Section 2.10(Pretreatment for Water Purification).

NOTE: External control contacts are normally closed, dry contacts.

2.10 Pretreatment for Water Purification

A water analysis of your feed water should have been performed, as part of the plan-ning and engineering that went into developing your RO system.

The water analysis will provide information on what type of pretreatment may berequired and what recovery the machine can be run at on the feed water provided. Ifthe machine is moved to a different water source, a new water analysis should betaken before operating the machine.

Your RO is designed to operate on tap feed water with an SDI) of 5 or less. The pHshould be in a range of 5.5 - 8.5. Exposure to any levels of chlorine may cause irre-versible damage to the Thin-layer composite (TLC) polyamide (PA) membrane ele-ments in your machine. Daily water checks are recommended to ensure the integri-ty of your pretreatment and RO system.

2.11 Machine Start-Up Preparation

Check the function and integrity of your pretreatment equipment. Ensure that yourwater softener and activated carbon filters have been leaked checked and properlyflushed, before starting up your RO machine.

CAUTION: Improperly flushed pretreatment may cause serious RO machineproblems at start-up.

2.12 Machine Start-Up

STEPS

1. Turn the feed water supply ON, while checking for leaks in the pretreatmentand inlet feed water lines.

2. Check to ensure power to the motor is de-energized and the ON/OFF buttonon the machine is in the OFF position.

3. Plug in the factory-supplied power for the control voltage.

4. For initial start-up, redirect the permeate and concentrate lines to the drain.

5. Open the concentrate and recycle flow control valves two complete turns.These valves are positioned on the flow control plumbing in the top right rearsection of the machine.

6. Turn the ON/OFF button on the machine ON. System will open allowing waterto flow through the machine to the drain through the permeate and concen-trate CIP valves.

Let the machine run to drain for 5 - 10 minutes. This provides a wet start-upof the pump and removes any air in the system.

7. Turn the ON/OFF button on the machine to the OFF position.

8. Re-energize the pump power and trigger the ON/OFF button on the machineto check rotation of the pump motor. Observing from the back of the pumpmotor, pump rotation should be clockwise. If rotation is wrong, de-energizethe pump voltage from the source and switch any two of the three-phasewires coming in on top of the three-phase starter. Re-energize the pump volt-age and re-check, to ensure correct rotation for the start-up and operation ofyour machine.

WARNING: IF THE RO PUMP IS STARTED WITH INCORRECT ROTATION(i.e., BACKWARDS), A NOTICEABLE DROP IN FLOWS ANDPRESSURES WILL RESULT. IF PUMP MOTOR OPERATES BACK-WARDS FOR ANY LENGTH OF TIME, PUMP DAMAGE MAYRESULT.

After correct rotation has been verified, you are now ready to start themachine and set the flows and pressures.

9. With the recycle and concentrate orifices still two (2) turns open and ade-quate feed water available, start the machine by turning the ON/OFF buttonto the ON position.

10. As the pump starts to build pressure, begin to adjust the orifices in the follow-ing manner: start by slowly closing the concentrate orifice while slowly open-ing the recycle valve.

Primary Pressure for Normal Operation at 77°F (25°C)

E4-Series: 220 psi (15.2 bar) at 77°F (25°C)

EZ4/E4LE-Series: 115 psi (7.9 bar) at 77°F (25°C)

While you are doing these valve adjustments, to obtain correct flows andpressures, observe the primary or pump pressure. The pump pressure, whileadjusting the orifices, should never operate outside of these ranges:

E4-Series Range: 190 - 275 psi (13.1 - 19.0 bar)

EZ4/E4LE-Series Range: 100 - 140 psi (6.9 - 9.6 bar)

8

The concentrate valve is drilled, and when completely closed the machine isrunning at the correct concentrate flow for a 75% recovery (Table 2.4, FlowSpecifications for E4-Series Machines).

If the temperature of the inlet feed water is not 77°F (25°C) use theTemperature Correction Factor Table (Technote 113). The proper adjustmentof the recycle and concentrate valves are critical to the correct operation ofthe machine.

CAUTION: Optimum recovery will vary according to water quality.

2.13 Temperature Correction Factor

If the temperature of the inlet feed water is not 77°F (25°C), refer to Technote 113 forTemperature Correction Factors.

NOTE: Optimum recovery will vary according to water quality.

9

2.14 Recovery

The machine flow specifications listed below are based on 25°C (77°F).

Table 2.4Flow Specifications for

E4-Series Machines

10

2200

50-75%

LPM/GPM

5.8/11.6

5.8/11.6

1.9/0.5

11.5/3.0

7.7/2.0

4400

50-75%

LPM/GPM

11.6/3.06

11.6/3.06

3.9/1.0

23.2/6.1

15.4/4.1

E4-Series

Recovery

Units

Permeate Rate

ConcentrateRate

(50%)

ConcentrateRate

(75%)

Feed Rate(50%)

Feed Rate(75%)

6600

50-75%

LPM/GPM

17.3/4.6

17.3/4.6

5.8/1.5

34.7/9.2

23.1/6.1

8800

50-75%

LPM/GPM

23.1/6.1

23.1/6.1

7.7/2.0

46.2/12.2

30.8/8.2

11000

50-75%

LPM/GPM

28.9/7.6

28.9/7.6

9.6/2.5

57.8/15.3

38.5/10.2

13200

50-75%

LPM/GPM

34.7/9.2

34.7/9.2

11.6/3.06

69.4/18.3

46.2/12.2

11

2.15 Autoflush Timer

2.15.1 Programming the Autoflush Timer

The Autoflush timer clock operates and displays in real time, but the Autoflushfeature will only work when the RO machine is operating. When the machineis operating in the Autoflush Mode, the total flow through the machine isincreased. This provides extra cross flow which flushes the loose foulantsfrom the surface of the membrane elements. When the machine is operatingin the Autoflush Mode a slight drop in permeate production, as well as adecrease in the primary and final pressures may be observed. An ideal wayto set the timer up is to program ten Autoflush sequences, with a 10 to 15minute duration, per 24 hours. To do this, follow the procedure below.

2.15.2 Setting Up the Autoflush Timer Clock

IMPORTANT: Before proceeding with setting the timer and programmingthe unit, press the RESET KEY to clear all data. After press-ing the RESET KEY, the display may show A.M., this is in mili-tary time mode.

If the machine is in Military Time, do the following:

Figure 2.2Setting-Up the Correct Time

on the Autoflush Timer

SELECTING AM/PM OR MILITARY TIME

After pressing reset , the display may showA.M.(right). The numbered day symbols will be flash-ing ON and OFF.

If the display does not show A.M., it is in military timemode (24:00 hr.). To change to A.M./P.M. mode, pressand hold the h Key and press the± 1h Key once, A.M. will appear in the display.

If display is in A.M.. mode and military mode isdesired, press and hold the h Key, press the± 1h Key once.

STEPS

1. While holding down the Clock Key (⊗), press the h key to advance tothe current minute.

2. While holding down the Clock Key (⊗), press the h key to advance tothe current minute.

3. While holding down the Clock Key (⊗), press the h key to advance tothe current minute.

NOTE: If the h and m keys are held down for longer than 2 seconds,the numbers will advance rapidly.

If the days are flashing, it indicates the day of the week was not setwhen setting the time. The timer cannot be programmed unless theday of the week is entered. Each year, in the spring, press the Buttonto advance the time one hour (Daylight Savings Time). In the fall,press the button to set the timer back one hour (Daylight SavingsTime).

2.15.3 Programming the Autoflush Timer Clock

This timer will accept up to 20 programs. Each program consists of the fol-lowing:

1. ON/OFF Command2. Time of Day (hours and minutes)3. Single day or multiple days

IMPORTANT: The current time of day and day of the week must be setprior to programming the timer. See Section 2.15.3 (SettingUp the Autoflush Timer).

12

2.15.4 Programming Twenty-Four Hour or Seven Day Schedules

NOTE: It is helpful to write out the program schedules before programmingthe time.

Example:

Figure 2.3Programming the Timer

2.15.5 Changing a Program

Select the program to be changed with the Prog. Key. A new set of days maybe selected with the Day Key just as in the initial programming. Hour andminute can be changed with the h and m Keys.

2.15.6 Deleting a Program

To delete one or a few programs: Press the Prog. Key until the desired pro-gram is displayed:

1. Press the m Key to :59 and press once again to blank out.

2. Press h Key to 11 P.M. and press once again to blank out.

3. Press the Clock Key, (⊗) display will flash for several seconds and thenenter the Run Mode.

4. Using the Reset Key will delete ALL programs, the time of day, and dayof the week.

13

2.15.7 Troubleshooting the Autoflush Timer

14

PROBLEM: Days are flashing, pressing any Key does nothing except“Hand” Key turns output ON and OFF.

SOLUTION: Time of Day and Day of Week have not been set .See Section 2.15.3 (Setting-Up the Autoflush Timer Clock).

PROBLEM: Time of day was set while holding the Clock Key down, butdays are still flashing.

SOLUTION: Current day of week was not set while holding downthe Clock Key. See Setting-Up the Autoflush Timer Clock(Section 2.15.2).

PROBLEM: It is 10 A.M. and a ON program for 8 A.M. was entered, but the output is not ON.

SOLUTION: The ON or OFF was not entered as part of the program.ON or OFF must be selected.

2.16 Calibrating the Conductivity Probe

STEPS

1. Make sure the calibration meter is in Measure Mode (with the MEAS LEDlight ON).

2. Immerse the Conductivity Probe in a 13.00 microSiemens (mS) prepared solu-tion.

3. Immerse and agitate Conductivity Probe, and wait for the reading to stabilize.

4. Calibrate the meter by adjusting the CAL adjustment screw until the LiquidCrystal Display (LCD) display reads 13 mS of the solution.

The meter is now calibrated

NOTE: The alarm function on the conductivity meter is not used on E4/EZ4/E4LE-Series machines.

Figure 2.4Conductivity Probe Display

15

2.17 Operation and Maintenance

The operation and maintenance of an E-Series RO machine requires regular datarecording and routine preventative maintenance. It cannot be emphasized enoughthe importance of filling out the Daily Log Sheet (Technote 106) during each operat-ing shift. A Start-Up Data Sheet (Technote 105) should have been completed at start-up containing pertinent facts on the operation of your machine. These two recordsare invaluable in diagnosing the performance of the equipment, and must be kept forreference. If you have questions concerning the operation of your machine or themethod of data recording, contact the manufacturer.

Three preventative maintenance procedures, which must be done on a regular basis,are as follows:

1. Change the pre-filter cartridges as needed. Pressure drop across the pre-fil-ters should not exceed 8 psi (0.6 bar).

2. Clean the RO membrane elements with approved cleaners at least quarterly,depending on feed water quality.

3. Flush the RO machine daily.

2.17.1 Daily Flushing for the Economy Model

If your E4-Series machine is an ECN Model it needs to be manually flusheddaily. The DLX E4-Series machine is equipped with an Autoflush Timer(Section 2.15, Autoflush Timer). A daily manual flush must be performed. Toflush the machine:

1. With the machine running, open the concentrate valve 1/2 - 3/4 turn.

NOTE: During flushing procedure, the machine must be running.

2. Allow the machine to operate with the concentrate valve open (Step 1)for 10 - 15 minutes.

3. After 10 - 15 minutes, return the concentrate valve to its previous set-ting, and return to normal operation.

CAUTION: When opening the concentrate valve, never allow themachine’s primary pressure to drop more than 10%below normal operating pressure.

2.17.2 Daily Flushing for the Deluxe Model

The DLX Model machine includes an Autoflush Timer Option. The AutoflushTimer Option automatically flushes the machine at presetintervals.

16

2.18 Pre-filter Cartridge

A 5 micron pre-filter cartridge is factory installed to protect the membrane elementsand valves from particles, which may be in the feed water. To order replacements,see the Spare Parts List (Technote 118, P/N 1233377).

A pressure drop across the filter of 8 psi (0.55 bar) or more during operation indicatesthat the pre-filters cartridge(s) need changing. Use only GE approved filters rated for5 microns or less. Do not attempt to clean used filters.

IMPORTANT NOTE: Failure to change the pre-filter cartridge according to theserequirements will void machine warranty.

2.19 Membrane Element Cleaning

GE recommends that you clean your RO every quarter, depending on the quality ofyour feed water. Cleaning of the membrane elements is vital because contaminantscan build up on the membrane element surfaces, reducing the permeate flow rateand affecting the quality of the permeate.

2.19.1 Step Wise Cleaning

This RO machine and many others have a centrifugal pump on them.Centrifugal pumps are not designed to draw water. They are designed tooperate with flooded suction only. The manufacturer recommends using aClean-In-Place (CIP), or booster pump, to provide water pressure and flow tothe RO machine pump from the CIP container.

2.19.2 Procedure to Clean with a CIP Pump

STEPS

1. With the machine running, open the CIP permeate valve, close thepermeate service valve and fill the CIP tank with permeate water.When the container is filled to desired level, turn machine OFF.

2. Add and mix up the cleaners in the CIP container. Please use onlyPA membrane element compatible cleaners.

3. Close the inlet feed water supply valve to the machine and open theCIP inlet feed water to the CIP container.

4. Close the permeate valve to point of use and also the concentratevalve drain.

5. Open the CIP valves, allowing permeate and concentrate to return tothe CIP container.

17

When set properly, the RO machine, the CIP pump, and the CIP con-tainer should be assembled in a loop configuration to recirculate thewater through the machine and back to the container during clean-ing. The size of the CIP container should be a minimum of three timesthe permeate rate.

CAUTION GE recommends the use of a CIP or booster pump toprovide the proper feed water pressure and quantityto the RO machine during cleaning.

Figure 2.5Clean-In-Place Pump

and Tank Hook-Up

With the machine set-up in the CIP configuration and the cleaning solutionmixed in the container, you are now ready to start the CIP process. Follow theSteps below.

STEPS

1. Check to ensure that the feed, permeate, and concentrate valves andline are open and unrestricted in the tank loop.

2. Start the CIP and RO machine pumps together. As they start up,observe all RO machine pressures and flows.

3. Recycle the cleaning solution for about 15 minutes. Damage mayresult to membrane elements if the temperature of the CIP solutionexceeds 105°F (40°C). If the water temperature exceeds 100°F (38°C),place bags of ice into the CIP container to absorb the extra heat.

4. After recirculating the cleaner for 15 minutes, shut down the RO andthe CIP pump.

18

5. Let the CIP solution dwell in the machine for 20 minutes.

6. After the 20 minute dwell time, start the CIP recirculation processagain for 10 minutes.

7. After the 10 minute recirculation time is complete, de-energize themachine. Then, open the inlet water line and route the concentrateand permeate lines to the drain.

8. Start the RO machine and flush to drain for 20 minutes. Verify the per-meate quality is good before returning to normal operation.

9. After permeate quality is verified as good, route the permeate to pointof use and concentrate to drain. You are now ready for normal oper-ation.

2.20 Suction Cleaning

GE does not recommend the suction cleaning method to clean the E4-Series ROmachine. If using suction cleaning, reference cleaning with a CIP pump above(Section 2.19.2, Procedure to Clean with a CIP Pump).

STEPS

1. Arrange the RO and the CIP container in a closed loop situation with thecleaning solution, reference Section 2.19 (Membrane Element Cleaning).

2. Move the L1 and L2 wires on the pressure switch across to the motor termi-nals (Figure 2.1, Three Phase Allan Bradley Motor Starter). The wires can alsobe temporally jumped.

3. Open the inlet feed valve.

4. Start the RO machine

5. As the machine starts up on inlet feed water, slowly close the inlet feed watervalve while slowing opening the feed water valve to the CIP tank.

You will begin to hear the RO pump draw the CIP solution into the machineand circulate it back into the CIP tank. After achieving prime, observe the ROclosely to ensure that you do not loose pump prime, which may result inpump damage.

6. Refer to the CIP cleaning procedure (Section 2.19.2) for cleaning steps.

WARNING: LOSS OF PRIME DURING SUCTION CLEANING MAY RESULT INSERIOUS DAMAGE TO THE PUMP.

19

20

NOTE: As previously mentioned, the manufacturer recommends useof a CIP or booster pump to circulate the cleaning solutionduring membrane element cleaning.

7. After suction cleaning cycle is complete, reopen inlet water and flush machineto drain for twenty minutes.

8. After permeate quality is verified as good, return machine to normal opera-tion mode.

2.21 Changing Out Membrane Elements

CAUTION: Replacement membrane elements are shipped from the factory in aplastic bag with a small amount of bactericide solution to prevent bio-logical growth. When installing the membrane elements, always pro-vide adequate ventilation and wear gloves while handling the mem-brane elements as recommended. The membrane elements must bekept moist at all times in to prevent possible damage to the mem-brane element material.

STEPS

1. Remove the top end caps and clamps from the membrane element housings.Lubricate all O-rings and brine seals, and the PVC membrane element stems(stingers) with a non-petroleum based lubricate (i.e., glycerin or poly water).

2. Load the down flow membrane elements first, by inserting the membraneelement into the membrane element housing with the brine seal end of themembrane element up. Slowly turn the membrane element as you lower itinto the membrane element housing. As you reach the bottom of the hous-ing slowly guide the PVC stem or stinger on the end of the membrane elementinto the head of the end cap. As the membrane element slides into the hous-ing the brine seal will be on the top.

3. Next, load the up flow membrane elements, by lubricating all brine seals, O-rings, and the membrane element stingers. With the up flow membrane ele-ment and the brine seal will be on the bottom of the membrane element. Turnthe membrane element slowly as you lower it down into the housing. As withthe down flow membrane element, one must slowly guide the PVC stinger onthe end of the membrane element into the end cap.

4. Reinstall the end caps by using non-petroleum based lubricant to lubricatethe O-ring inside the end cap. Reinstall the end cap on the membrane ele-ment by first, aligning the stinger into the hole in the end cap and then turnthe end cap slowly clockwise, as you push it down into the membrane ele-ment housing.

21

5. Reattach the housing clamp and tighten.

6. Next reconnect the permeate and concentrate lines.

The machine is ready for start-up.

2.22 Troubleshooting

This troubleshooting guide can assist you in identifying common operating problems youmay experience with your machine. Many of these problems can be easily corrected by theoperator, however, for those that persist or are not understood, you should contact the GE Customer Support Center. Have the following information available when calling theCustomer Support Center:

1. Machine installation date

2. Model number

3. Serial number

4. Weekly log sheets

5. Detailed description of problem.

22

POSSIBLE CAUSE

Insufficient feed water pressureor flow

Clogged pre-filter

High flow rates

Dirty or fouled membraneelements

Solenoid valve not opening

PROBLEM

Low OperatingPressure

SOLUTION

Open the feed pressure, open thefeed water valve, check for

restrictions

Replace the cartridge.

Close the concentrate valve, checkthe permeate and concentrate flow

rates and adjust if necessary.Excessive permeate flow may indi-

cate a damaged O-ring.

Flush and clean the membraneelements.

Clean or replace the solenoid valve.

T R O U B L E S H O O T I N G G U I D E

23

POSSIBLE CAUSE

Pump rotating backwards(three-phase power only)

Insufficient electrical power

Pump not operating correctly

Low operating pressure

Dirty or fouled membraneelements

Operating on cold water lessthan 55°F (13°C)

Membrane elements installedbackwards or damaged

concentrate seal

Flow meter inaccurate

PROBLEM

Low Operating(continued)

Low Permeate FlowRate

SOLUTION

Switch any two of the three-phaseleads to the motor starter.

Check the fuses or circuit breaker,measure the voltage.

See pump instructions.

See possible causes for lowpressure.

Flush and clean membraneelements

Install a hot/cold feed water tem-pering valve if more permeate flowis needed. Operate with a feedwa-

ter temperature of 72° - 75°F(22° - 25°C).

Install membrane elements in thedirection of fluid flow. Flush andclean the machine immediately.

Membrane elements with damagedconcentrate seals should be

cleaned and may be returned forrepair.

Check the flow rate manually with astop watch and calibrated

container.

T R O U B L E S H O O T I N G G U I D E

24

POSSIBLE CAUSE

Concentrate valve plugged

Concentrate outlet linerestricted

Flow meter inaccurate

Dirty concentrate valve

Recycle or concentrate valveplugged

Inaccurate pressure gauge

Restricted or reducedpermeate flow rate

Restricted flow afterpump outlet

PROBLEM

Low concentrate flowrate, normal or higherthan normal pressure

High operating pressure

Excessive pressure drop[over 50 psig (3.0 barg)](high primary pressure -

low final pressure)

SOLUTION

Remove the concentrate valve stepand/or disassemble the plumbing.

Clean the valve

Examine the concentrate line forobstructions or kinks, repair or

replace the tubing.

Check the flow rate manually with astop watch and calibrated

container.

Disassemble and clean theplumbing to the valve

Disassemble the plumbing to therecycle valve and remove foreignparticles. Check the concentrate

valve stem.

Replace or calibrate the gauge asrequired.

See possible causes for lowpermeate rate.

Check for blockage of the concen-trate flow at the inlets and outlets of

the membrane element housings.

T R O U B L E S H O O T I N G G U I D E

25

POSSIBLE CAUSE

Telescoped membrane elementcovering membrane element

housing outlet port

Severely fouled or dirtymembrane elements

Inlet solenoid valve not closingor seating properly

Dirty or fouled membraneelements

O-ring seal broken or damaged

Change in incoming waterquality

Inaccurate conductivity monitoror fouled probe

PROBLEM

Excessive pressure drop[over 50 psig (3.0 barg)](high primary pressure -

low final pressure)(continued)

Water flowing whenmachine is turned OFF

Declining rejection(high permeate

conductivity)

SOLUTION

Flush and clean the membraneelements

Flush the machine then clean it withdetergent.

Clean or replace the valve. Cleanthe membrane elements with deter-gent immediately. Water must not

pass through the inlet when themachine is OFF.

Flush and clean the membraneelements

Replace the O-ring, check the seal-ing surfaces on the O-ring groove,

interconnectors and end caps.Replace the damaged parts.

Open the concentrate valve andflush. Test the water for pH, hard-

ness, TDS and iron content. A wateranalysis should be sent to GE

Infrastructure for review.

Calibrate the monitor with a DSstandard solution or check the

readings with another conductivitymeter. Replace or clean the probe.Check the connections between the

probe and monitor.

T R O U B L E S H O O T I N G G U I D E

26

POSSIBLE CAUSE

Pressurized storage switch orfloat switch has cut power to

machine

Fluid temperature higher than100F (38C) or thermal overload

in motor

No power to machine

Motor and/or pump notoperating properly

Alarm condition has turnedmachine OFF

Motor starter overloaded, heatertripped

Timing relay defective/burnedout

PROBLEM

Switch ON, unit notoperating

Deluxe (DLX) electricalmachine shutdown

SOLUTION

Check the permeate back pressureor position of float in the storage

tank.

Allow the machine to cool; checkthe feed water supply and/or amp

draw to the motor.

Check the fuses or circuit breakers,measure the voltage.

See the pump instructions. ContactGE Infrastructure for possible repair

or replacement.

Restart the machine by pushing thealarm bypass. Check all possiblealarm conditions: inlet pressure or

motor starter overload

Turn the switch OFF. Rest theheater(s). Check the motor amp

draw and the line voltage.

Replace the relay.

T R O U B L E S H O O T I N G G U I D E

For more information call 952-933-2277 or 800-848-1750 in the U.S., or visit www.gewater.com.

© 2005, General Electric Company. All rights reserved.P/N 1161875 Rev. D

North American Sales Euro/Africa Sales Asia/Pacific Sales5951 Clearwater Drive 230 rue Robert Schurman 1044/8 SOI 44/2Minnetonka, MN ZA des Uselles Sukhumvit Road Parkanog55343-8995 77350 Le Mée sur Seine Bangkok 10110USA FRANCE THAILAND(952) 933-2277 Phone +33 1 64 10 2000 Phone +66 2 38 14213 Phone(952) 933-0141 Fax +33 1 64 10 3747 Fax +66 2 39 18183 Fax

GE InfrastructureWater & Process Technologies